Dyeing machines

RBNV-IVERTICAL DYEING SYSTEM

Dyeing machines

1

The pioneering in 1985 of fully automated and roboti-zed yarn dyeing plants based on RBNV dyeing machi-nes and the realization of numerous large plants in thelast 30 years, have proven the market impact of this in-novative system, backed by years of technological rese-arch and development activities and continuous

dedication to all details of engineering, manufacturing,testing and servicing.Performance, reliability and technological life are basedon a wide range of major technical features summarizedin this pamphlet.

Fully robotized dyeing plant for worsted bumps and weaving yarns. No.18 RBNV dyeing machines with VLS variable loading and coupling systems. Batches from 10 up to 1400 kgs per color.Robotized material transport systems from greige warehouse till delivery.Centralized kitchens HP linked with computer dispensing of powder dyes and liquid chemicals. Host computer with Tintoretto software package for dyehouse planning and management.

VERTICAL DYEING SYSTEM

2

AIR PAD PRESSURIZATION

RBNV-I, as all Loris Bellini dyeing machines since the be-ginning of the 50’s, is Air Padded. RBNV-I dyeing machinecan be rapidly pressurized at 5 Bar at low liquor tempera-ture. The relevant advantages to this solution are:

Ecology and environment:• Lower Consumption: Only pump and carrier volumes

are flooded, with reduction of liquor ratio to a mini-mum water, steam and power consumption. Substan-tial savings are realized in term of cooling water (nocooling of liquor before expansion tank), steam (no re-heating of liquor back to dyeing temperature) andelectric power.

• Low Emissions: The air pad operates as a doublechamber to reduce heat emissions in the dye-house.NO external Expansion Tank means no emission ofchemical vapours. NO external Expansion Tank means no continuousexternal circulation, thus liquor expansion volume rea-lized directly into the autoclave.

• Dyestuff exhaustion is perfectly equalized.

• Air pad pressurization allows to inject dyestuffs andchemicals directly into the main liquor circuit bymeans of single tank or a multi tank colour-kitchen.

Dyestuffs are injected into the highest turbulencepoint of liquor circulation pump, in order to originatean intensive stirring effect.

• Air Pad Pressurization allows the machine to be stan-dard equipped with dynamic HYDRO-EXTRACTIONDEVICE by compressed air:

- Elimination of unfixed dyestuff increases colourfastness.

- Preliminary water squeezing which avoids carrierdropping and helps the centrifuging operation.

• VAT DYEING: During cotton dyeing with VAT dyestuffsthe dyeing liquor is not subject to a continuous oxi-dation by external air.

- Sodium hydrosulphite is just added right at thestart in limited stoichio-metric quantity.

- No continuous additions during dyeing cycle tocompensate external oxidation in expansion tank.

- No intermediate checking of reduction level isneeded.

• Dyeing liquor temperature remains perfectly steadyat set value, due to absence of continuous liquor coo-ling/ reheatin.

Dyeing machines

3

ADJUSTABLE LIQUOR RATIO

Liquor ratio is adjustable to optimize processing condi-tion, by means of automatic liquor level control.Level control is of continuous type and liquor level can bepreset along the full height of the kier.RBNV-I operates at:

A. Low liquor ratio during dyeing phase

In dyeing phase RBNV-I dyeing machines operate with li-quor ratio from 1:4 to 1:8 in function of yarn package den-sity.Low liquor ratio during dyeing saves process water, steamand auxiliary products added in fixed concentrations inrelation with liquor volume (detergents, salts, etc.) anddetermines economical dyeing costs.

B. Higher liquor ratio during wash-off phase

Adoption of higher liquor ratio during wash-off phase im-proves the solubility of unfixed dyestuffs.Higher liquor ratio allows forperforming soaping and wash-off phases after cottondyeing with fibre reactive or VAT dyes at a liquor ratio ran-ging from 1:8 to 1:13, with substantial improvement ofcolour fastness and reduction of total dyeing times.Besides continuous level control, RBNV-I can be filled witha set volume of water by an optional water predetermi-ned-counter.

4

FLEXIBILITY

Quick response to market demand has made flexible loa-ding mandatory. RBNV-I machine operates at will with fullload or reduced load in conditions of practically constantliquor ratio. The machine operates at:

Half loadReduced loadFull load

The variable loading system OPERATES ON ALL KINDS OFMATERIALS to be dyed, as rigid or compressible yarn pac-kages, tops, bumps, loose stock, tow, with the adoptionof interchangeable modular dyeing carriers. Pump flowrate is regulated to remain constant at reduced load.The AUTOMATIC COUPLING SYSTEM with total liquor ex-change among two or three RBNV-I machines permits toextend further the flexibility for dyeing of large batches.

VLS Variable loading System dyes at constant liquor ratio and flow rate.

Dyeing machines

5

6

Dyeing machines

7

HELICOCENTRIFUGAL PUMP

The heart of RBNV-I dyeing machine is the inimitable HE-LICOCENTRIFUGAL type liquor circulation pump, which isa mixed design between an axial and a centrifugal impel-ler, specifically designed to cover the complete range ofdifferential pressures (Delta P) from 0.2 up to 2.5 Bar.

In fact, nowadays, dyeing mills have to be able to processa huge variety of fibres and yarns, from high permeabilityas acrylic and wool (0.2 to 0.8 Bar) up to low permeabilityas cotton, viscose and cuproammonia rayon (0.8 to 1.5Bar), or the super dense Polyester packages (up to 2.0 Bar),in the same dyeing machines at the best conditions. Shaftof motor always rotates in a single direction. Motor doesnot stop during flow reversal.

Automatic reversal of liquor flow direction is performed atpreset time intervals by means of a special Flow ReversalDevice (RD) integrated into the pump and consisting of arotating elbow which slides sideways the delivery mou-thpiece from inside-out (I-O) to outside-in (O-I) directionand vice versa. Precision positioning of reversal curve isoriginated by a combined pneumatic-oleodynamic sy-

stem (PC), in order to perform a very smooth liquor flowreversal without hammering effects.

The final result is an outstanding dyeing evenness, evenin critical dyeing conditions.Liquor flow reversal is made with motor in operation inorder to avoid peak power absorption due to delta-starmotor restarting.The circulation pump is equipped with cooling-free andmaintenance-free mechanical seals.The helicocentrifugal pump with built-in liquor reversalsystem allows an hydraulic circuit of compact overall di-mensions, with all components laid out in function ofeasy inspection and maintenance. The helicocentrifugalpump has been entirely engineered by Loris Bellini, andeach one is tested on our own computer controlledpump testing centre.

As all parts, where an inspection could be foreseen, thepump is connected to the kier by two parallel piping, bymeans of flanges for easy installation, and to allow futureinstallation of flow meter device (optional).

8

THE OPTIMIZED DYEING

As all new generation Loris Bellini yarn dyeing machineRBNV-I is equipped with: • INVERTER for step-less pump speed control, which

operates pump speed with accuracy of 1 PM and savesup to 40% of electric power consumption on high per-meability yarns. Pump speed is controlled automati-cally for both Inside-Outside and Outside-Insidedirections.

• ADPS. An automatic differential pressure control sy-stem. Which monitors and controls differential pres-sures Inside-Out and Outside-In of material andadjusts automatically the pump operating speed tomaintain the preset value of differential pressure.ADPS was pioneered several years ago and still re-mains the best control system for color repeatabilityin package dyeing. After optimum values of differen-tial pressures for a specific yarn package are memori-zed into the controller of the dyeing machine, theADPS system automatically regulates the liquor flowrate by acting directly on pump speed, in order tooperate in the dyeing process under constant para-meters for color reproduction. ADPS sets values diffe-rentiated in terms of flow direction, operating phase(ex: high flow rate at critical dye exhaust temperature,low flow rate during bleaching) and yarn packagetype in analogical form and regardless of other condi-tions (temperature, static pressure, etc.) which are con-trolled independently. ADPS also operates as a safetysystem: in case of a leakage from a locking cap it in-

creases automatically the pump speed by acting di-rectly on the Inverter to compensate the loss. It alsoprovides on-line automatic control on pump speedand reversal device.

• Signalling and alarm of ERRONEOUS DIFFERENTIALPRESSURE VALUES.

• Signalling and alarm of CIRCULATION PUMP STOP-PED.

The ADPS system permits to obtain an excellent controlof physical dyeing parameters with results of colourshade repeatability, flexibility regardless of loading rateand densities, rapid dyeing, reduction of power con-sumption.

Optional • MAGNETIC FLOWMETER: normally for Polyester and

worsted Wool tops plant, the pump can be driven bya real- time flow rate monitoring and control. This clo-sed-loop system permits to set a In-Lab predetermi-ned Flow Rate Value, and keep it constant despite theDelta P variation due to the change of the fibre per-meability during the process. The liquor flow rate re-gulation system allows to adopt the best dyeingconditions in function of the material under process(yarn, tops. tow, loose, stock), type of fibre (cotton, po-lyester, wool, etc.) dyestuffs classes, material densityand permeability.

Dyeing machines

9

MODULAR DESIGN

RBNV-I dyeing machines are engineered for modular con-struction on the basis of autoclave internal diameter anduseful dyeing carrier height.Standard industrial machines can be selected among aseries of optimized sizes, which ensure to always operatein the most convenient MLR conditions, according to thepackage type and size. Special dimensions according toCustomer's requirements are available on request.Large size machines, up to 2500 kg/batch in single kier,can be supplied on demand

MODULAR CONSTRUCTION is extended also to:• Liquor circulation pumps • Automatic pneumatic on-off valves • Additional tanks • Liquor preparation/recovery tank and relevant tran-

sfer pumps

The modular design determines a homogeneous, reliableand expandable system for integrated dye-houses and al-lows an easier technical assistance, as well as a more re-liable spare parts and service management.

INTERCHANGEABLE DYEING CARRIERSRBNV-I dyeing machines use interchangeable carriers for:• yarn packages (cylindrical conical, biconical, com-

pressible types) diameters from 110 to 270 mm• yarn on muffs and cheeses• Worsted tops with bumps up to 50 kg• Loose stock fibre• Tow• Yarn warp beams and fabric beams• Special applications as ribbons (decoration and zip-

pers), roving slivers (linen), cotton loose stock (medi-cal cotton-wool) etc.

10

MACHINE PROCESS MANAGEMENT

"Leonardo" Industrial PC machine controller.RBNV-I dyeing machines can be supplied with LeonardoPC computers designed to be optionally interfaced to acentral host computer station for dyehouse management.Leonardo operates on industrial PC with features of:• Reliability in dye-house operating conditions up to

50°C room temperature.• Touch Screen interface for easy programming • "Multitasking" operation.• Presetting for network connection with external com-

puter for centralize dye-house management • Machine configuration simply by software.• Automatic fault finding system

- temperature outside range- lack of compressed air, - exclusion of safety systems- failure of motors and main valves- failure of level and temperature probes with di-

splay of cause of fault for immediate identificationand maintenance.

OPTIONSRBNV-I is a full all-round system. Dyeing machines can besupplied on request with a wide range of optional such as:• HT Draining Device, which enables to drain liquor at

130°C for total Oligomer elimination during Polyesterdyeing process. It operates on the individual machine,without underground works. It consists of: one stain-less steel liquor blending vessel, one automatic waterdrain valve, one temperature probe and relevant con-trol equipment, one modulating proportional auto-matic cold water inlet valve and connection device.

• Exponential/Linear Alkali Dosing system Mod DL.EXCLUSIVE Loris Bellini system which permits the al-kali (but also dyestuff or auxiliaries) introduction wi-thout changing the liquor ratio, perfectly followingthe designed introduction Volume/Time Curve. It con-sist of:- continuous levels in dye kitchen tanks, automatic

liquor recycle valves- dedicated software for RBNV-I microprocessor

• Automatic liquor preparation recovery tank. Liquor preparation/recovery tank is designed to con-tain over 100% of machine liquor volume. It is equip-ped with automatic water filling valve (s)

• FLANGED indirect steam heating coils with modula-ting proportional valve.

• tank closing lid

• automatic CONTINUOS liquor level controls• Transfer/Mixing Pump, with connection piping, recir-

culation piping for mixing operation and automaticcut-off valves

• liquor drain valve (s)• tank washing system by large perforated coil• connection piping with the Colour kitchen tanks

The preparation/recovery tank allows to eliminatedowntimes of the dyeing machine, feeding it with aprecise quantity of liquor at preset temperature, withdyes and chemicals perfectly mixed.It is an absolute must for cellulosic based yarn.

• Automatic coupling systemThe system operates by total liquor exchange withthe following features:

• cross flow exchange piping • Liquor level equalization, (exclusive in Loris Bellini),

by means of a water level equilibration tube linkingthe two kiers and a static air pressure levelling tubelinking the two air pads

• master/slave control panel and microprocessor ope-ration. Coupled machines can operate single (two se-parate colour shades) or coupled (same shade).

RBNV-I FEATURES:• Standard design and manufacturing features:• Nominal loading capacities from 5 to 1500 kg.• Dynamic Hydro extraction Device. • Pressure rating of 5.0 kg/cm2, up to 160°C tempera-

ture, temperature lock at 140C.• Construction in AISI 316 stainless steel, for all the

part in contact with dyeing liquor.• Water protected motors (IEC Standards IP54).• Waterproof electrical equipment (IEC• Three-level safety systems.• Magneto-thermal motor protections.• Heat exchangers rated for 15.0 kg/cm2 operating

pressure.• Heating gradient 5°C./minute (range 20-80°C steam

pressure 6.0 kg/cm2) Cooling gradient 3°C./minute(range 130-108°C water temp. 15°C, pressure 1.5kg/cm2).

• Pneumatic lid lifting and lowering.• Rapid lid locking system.• Design, manufacturing and testing in accordance

with: PED/97/23/CE, ASME-CODE International Pres-sure Vessel Standards.

Dyeing machines

Via XI Febbraio, 26 Bollate (Milano) ItalyPhone +39 02 3330871 Fax +39 02 3501665

www.lorisbellini.com E-mail: info@lorisbellini.com

prin

ted

on e

colo

gica

l pap

er